Doosan G20E-5 manuals

Doosan G20E-5 Service Manual (326 pages)

Brand: Doosan | Category: Engine | Size: 13.71 MB |

English

Table of contents

Service Manual

1

Important Safety Information

2

Chapter 4. ENGINE ELECTRICAL

5

Chapter 5. ENGINE MANAGEMENT

5

SYSTEM (EMS)

5

Chapter 6. LPG FUEL DELIVERY

6

Chapter 7. MPI GASOLINE FUEL

6

DELIVERY SYSTEM

6

Precautions before Service

8

Replacement Part

9

Rubber Parts

9

Oil and Grease

9

Genuine Part

9

Electrical System

9

CAUTION

10

Tightening Torque

11

Recommended Lubricants

12

Lubricant Capacities

12

General Specification

14

Engine Power and Torque

16

General Maintenance

17

Engine Oil Classification

18

Checking Engine Oil Level

19

Checking Compressed Pressure

20

Cooling System Maintenance

22

Checking coolant leaks

23

Specific gravity test

23

Adjusting

25

Checking Belt for Damage

25

Ignition System Maintenance

26

Fuel System Maintenance

29

Pressure Regulator/Converter

30

Exhaust System Maintenance

31

Maintenance Schedule

32

Torque Specification

39

Timing Belt System

43

Removal

44

Assembly

47

PCV Valve

49

Service Procedure

50

Intake and Exhaust System

51

Exhaust Manifold

53

Cooling System

55

Testing and Adjusting

56

Coolant Pipe and Hose

61

Water Pump

62

Thermostat

64

Cylinder Head Assembly

66

ASSEMBLY

73

Lubrication System

75

Instrument Panel

77

(1) Engine Oil Light

77

Oil Pressure Switch

78

Front Case and Oil Pump

79

CAM Shaft, HLA, Timing Chain

84

Crankshaft

91

Disassembly

92

Flywheel and Housing

95

Piston and Connection Rod

96

Engine Block

102

Inspection

106

Cylinder Block

111

Piston Pins

114

Reassembly

114

Specifications

119

Ignition System

120

Misfires

121

COP Checks

121

(Power TR)

123

Inspection of Ignition Coil

124

Inspection of Spark Plug

125

Charging System

127

Components

128

Troubleshooting

129

Troubleshooting Procedure

130

Disassembly and Installation

135

STARTING SYSTEM

140

Diagnosis Procedure

141

Start Relay Tests

143

Starter

145

Removal and Installation

146

Inspection (After Removal)

146

General Information

151

Service Standard

156

Component Location

157

General Description

161

LPG Fuel System Operation

164

Electronic Throttle System

172

Exhaust System

174

CAUTION—PROPER WIRING

179

EMS Inspection and Repair

190

Camshaft Position Sensor

192

Crank Shaft Position Sensor

193

Sensor

194

IAT (Intake Air Temperature)

195

L4GC215A

196

[CIRCUIT DIAGRAM]

197

[HARNESS CONNECTORS]

197

LP Fuel Temperature Sensor

200

Angle Sensor-Accelerator

201

Electronic Throttle Body

204

WARNING - PROPER USE

205

Hose Connections

206

Removal and Installation of

207

N-2007 LP Regulator

207

Tests and Adjustments

210

WARNING—PROPER USE

210

Idle Mixture Adjustment

214

Parts Description

217

WARNING – PROPER USE

221

Regulator/Converter

223

CA100 Disassembled Service

234

Figure R3

237

Figure R4

237

Figure R5

237

Figure R6

237

Figure R8

238

Figure R9

238

Figure R7

238

N2001 Disassembled Service

239

Specification

240

Special Tools

240

Components Location

241

Fuel Pressure Test

242

Fuel Presure Test

243

Injector

244

Schematic diagram

245

Injector Inspection

246

Installation

247

Fuel Pump

248

Preliminary Checks

249

Basic Troubleshooting Guide

250

Basic Inspection Procedure

251

WARNING

251

Basic Troubleshooting

262

Surges and/or Stumbles

263

Acceleration

266

Acceleration (cont’d.)

267

Detonation / Spark Knock

268

Dieseling, Run-on

269

Backfire

269

Cuts Out, Misses

272

High Idle Speed

274

Displaying Fault Codes (DFC)

278

Clearing Fault (DFC) Codes

278

Fault Action Descriptions

279

Fault List Definitions

279

Appendix

308

Service Tool Display

310

Copy the .dll file to the

315

TDDBLL directory

315

Copy the .mfu update file to

315

Select “SECM-1” in the

316

Ground Speed Limits (Option)

319

LPG And LPG Fuel Tanks

321

LPG Fuel Tanks

322

Installing LPG Fuel Tanks

322

LPG Fuel Tank Components

322

Fuel Gauge

323

Service Valve

323

Quick Disconnect Coupling

324

Filler Valve

324

Regulatory Compliance

325

Abbreviations

326

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